Engineering Manual Common

MN A 00100 Manual

Civil and Technical Maintenance (extracted from formerly ESC 100) Version 1.6

Date in Force: 27 June 2019

UNCONTROLLED WHEN PRINTED

Superseded by MN A 00100 v1.7, 30/08/2019 Trains Engineering Manual – Common Civil and Track Technical Maintenance (extracted from formerly ESC 100) MN A 00100

Approved Ken Chong Authorised Jonathon McKinnon by: Professional Head by: Engineering Technical Civil Engineering Publications Manager Engineering System Integrity Engineering System Integrity

John McLeod Professional Head Track Engineering Engineering System Integrity

Disclaimer

This document was prepared for use by Sydney Trains or its contractors only. All Sydney Trains engineering documents are periodically reviewed, and new editions are published, between editions, amendments may also be issued. It is the document user’s sole responsibility to ensure that the copy of the document they are viewing is the current version including any amendments that may have been issued. Errors or omissions in this document should be reported to Sydney Trains. Sydney Trains makes no warranties, express or implied, that compliance with the contents of this document shall be sufficient to ensure safe systems or work or operation.

Document control

Version Date Author Summary of change 1.0 5 May 2016 A Khan First issue as Sydney Trains document, extracts from formerly ESC 100 Updated changes in bridges, track clearance, Lubricators TMPs 1.1 9 May 2016 A Khan Revert changes to overbridges, footbridges and culvert TMP - pending implementation 1.2 30 September 2016 A Khan Remove references TN065 & TN068 for underbridges 1.3 13 June 2017 A Khan Added Thornley Lever detailed service, updated section A-9 - Earthworks & A-11 Routine Cleaning, Updated Appendix D section D-1 1.4 21 August 2017 A Khan Updated References (section 2.1), Appendix C Updated Revtar to RevCom, Added Concession SW0175:2016 1.5 18 June 2018 A Khan Minor updates to Appendix A1, A5, A9, A12 & Appendix C 1.6 27 June 2019 James Ning Added Racor Lever Examination and Servicing, Edited Standard job number

© Sydney Trains Page 2 of 47 Date in Force: 27 June 2019 UNCONTROLLED WHEN PRINTED Version 1.6 Superseded by MN A 00100 v1.7, 30/08/2019 Sydney Trains Engineering Manual – Common Civil and Track Technical Maintenance (extracted from formerly ESC 100) MN A 00100

Summary of changes from previous version

Summary of change from version 1.5 to version 1.6 Section Added existing Standard job number to remove duplicability (Track Patrol) A-1, P13 Changed Standard job number to remove duplicability (Test Weld) A-2, P17 Added Examination of Manual Point Lever (Racor Lever) A-5, P21 Added Servicing of Manual Point Lever (Racor Lever) A-5, P21 Changed Standard job number to remove duplicability (Expansion switch A-5, P22 examination) Added existing Standard job number to remove duplicability (Detailed Structures 30/08/2019 A-11, P25 Examination) Created SSC to include 217 to remove duplicability for 207(Servicing of Bearings) A-11, P28 Summary of change from version 1.4 to version 1.5 Section Definitions and Abbreviations update in table 3, P8 Change from SAP to Transport Equip 8.6, P11 Updated Standard Job number A-1, P14 v1.7, Updated frequency of Inspection of Crossing condition A-5, P21 Updated Standard Job number A-9, P24 Frequency and Latitude Update A-12, P28 Inclusion of Tunnels in Integrated Track Patrol in Appendix C Table 3, P36 Inclusion of EI 14/03 - MTP Camera Failure Protocols Appendix C P34 Summary of change from version 1.3 to version 1.4 Section Updated Reference documents Section 2.1 Updated Revtar to RevCom Section 3

00100 Updated all concrete or masonry culverts and separated steel culverts A-11 page24 Updated transom type – ASA product type approval PTA CI001 2016 A-11 page25 Amended dot point in table 2 page 36; Appendix C A • MTP to occur every 14 days, with imagery review within 24hrs of patrol (MTP can occur on 15th day, with imagery reviewed within 24hrs of patrol) Updated wording • (Regime may also be used in Hi-Rail Patrol lengths in Outer Suburban & Regional areas) Amended dot point in table 3 page 37; Appendix C MN • MTP to occur at least every 14 days, with imagery review within 24hrs of patrol (MTP can occur on 15th day, with imagery reviewed within 24hrs of patrol) Updated wording • (Regime may also be used in Hi-Rail Patrol lengths in Outer Suburban & Regional areas) by Removed section D2 table 9 – pending approval Appendix D Summary of change from version 1.2 to version 1.3 Section Note: EI C 17/01 (Inspection of Direct fixed track slab in tunnels & on bridges) MN C 10110 All Actions are incorporated in Service Schedule SSC227 in MN C 10110 EI T 16/14 (prefix in v 1.2) removed as FFU is added with Timber Sleeper A-1, A-3, A-5 EI A 16/01 (prefix in v 1.2) removed & Note for Axle counters added 4.1 – P8 Section 7.1: “Authority to Waive” added 7.1 – P10 Section 8.8: “TMP Implementation” added 8.8 – P12 EI T 16/05 (prefix in v 1.2) removed & SSC017 added for of manual A1 – P13 levers in and Yards Updated Rail Lubricator examination (All Electrical Remotely monitored lubricators) A2 – P19 EI T 16/05 Added SSC066 for complete service of manual interlocking levers A5 – P19

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Added definition of heavy rain (>50mm in 24 hours) A6 – P21 Added comments in General examination of Cutting & Embankments (not risk A9 – P23 assessed) Added latitude and comments in Detailed Examination to Cutting & Embankments A9 – P23 (not risk assessed) Updated geotechnical risk site examination and review section A9 – P24 Moved pedestrian subway from underbridges to culverts A11 – P24 Added Surface drain/ Track Slab & Subsurface drain Routine Cleaning - Jet / A11 – P288 Hydrovac Added following statement in section D-1, "ensure the output from engineering Appendix D assessment is uploaded in the appropriate database" Page-41 30/08/2019 Summary of change from version 1.1 to version 1.2 Section Updated Appendix D at page 39, added underbridges functions on page 25. “All steel or concrete underbridges including flyover, dives, multilevel stations, pedestrian subway” Appendix D Added table 8 & 9: condition assessment of underbridges Updated examination regime for all cuttings and embankments which are not risk assessed Appendix A v1.7, Moved Buffer stops from Detailed Structures Examination to A-8, Track Equipment Appendix A Added new column for standard job numbers Appendix A 00100 A MN by

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Table of Contents

1 Purpose ...... 7 1.1 Scope and Application ...... 7 2 References ...... 8 2.1 Sydney Trains / Transport of NSW Documents ...... 8 3 Definitions and Abbreviations ...... 9 30/08/2019 4 Maintenance Concept ...... 10 4.1 General...... 10 4.2 Preventive Maintenance...... 10 4.3 Corrective Maintenance ...... 10 5 Competency ...... 10 6 Safety Importance ...... 10 v1.7, 7 Management and Reporting ...... 11 7.1 Authority to Waive ...... 11 8 Technical Maintenance Plan User Information ...... 12 8.1 Asset ...... 12 8.2 Service Description ...... 12 8.3 Safety Importance ...... 12 8.4 Applicability ...... 12 8.5 Service Schedule Reference ...... 12 00100 8.6 Period ...... 12 8.7 Latitude ...... 13

A 8.8 TMP Implementation ...... 13 9 Tailored Technical Maintenance Plans ...... 13 10 Changes to TMP's and Updates ...... 13 Appendix A Technical Maintenance Plan ...... 14

MN A-1 – Track System ...... 14 A-2 – Rail System ...... 18 A-3 – Sleepers / Bearers ...... 21 A-4 – Ballast ...... 21 by A-5 – Turnouts ...... 21 A-6 – Drainage ...... 23 A-7 – Train Monitoring Equipment ...... 23 A-8 – Track Equipment ...... 23 A-9 – Earthworks ...... 24 A-10 – Level Crossings ...... 25 A-11 – Structures ...... 25 A-12 – Right of Way ...... 29 Appendix B Detailed Plain Track Rail Testing Schedule ...... 30 Appendix C Implementation of Varied Track Patrol Arrangements ...... 33 C-1 – Adjacent Track Patrol and Night Patrol ...... 33

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C-2 – Engine Patrol ...... 33 C-3 – Integrated Track Patrol Regime ...... 34 C-4 – Applicability ...... 40 C-5 – Mandatory Requirements for Operation of the Integrated Walking Regime: ...... 40 C-6 – Mandatory Requirements for Mainline Track Sections: ...... 40 C-7 – Mandatory Requirements for Ancillary Line Track Sections: ...... 40 C-8 – Conditions Requiring Supplementary Patrol ...... 40 C-9 – Plain track ...... 41 C-10 – Turnouts and Special Trackwork ...... 41

30/08/2019 C-11 – Ancillary Lines ...... 42 Appendix D Examination Frequencies for Underbridges ...... 43 D-1 – Engineering Assessment (EA) ...... 44 Appendix E Tailored Technical Maintenance Plans ...... 47

v1.7, 00100 A MN by

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1 Purpose This document sets out the Sydney Trains maintenance policy for civil in terms of mandatory preventive maintenance and minimum service frequency by asset type.

It is applicable to all track and civil infrastructure maintained by Sydney Trains.

1.1 Scope and Application

30/08/2019 The Technical Maintenance Plan (TMP) specifies the level of maintenance required for assets within the Track and Civil disciplines. This document is provided for the use of personnel responsible for programming preventive maintenance activities.

The TMP lists items when:

• They are repairable. • They have a defined maintenance policy (i.e. the item has a scheduled v1.7, maintenance activity at a defined interval). • They require some special maintenance management input and thus will need certain information to be recorded. The TMP specifies:

• which items are to be maintained, • what maintenance is carried out, • when maintenance is required, and 00100 • requirements for managing and reporting compliance with standards for nominated scheduled maintenance tasks.

A The maintenance tasks and minimum frequencies defined in this document are mandatory for all track and structures assets maintained by Sydney Trains.

Any proposed reduction in task scope or frequency (lengthening time between tasks) shall be approved, as appropriate, by the Manager, Technical Maintenance Plans, in a location-specific tailored TMP. Tailored TMPs, where approved, are listed for reference in Appendix E. MN

Maintainers shall also review any atypical situations, consider if more stringent requirements are appropriate and ensure appropriate defect management is carried out. by

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2 References Note that references to RailCorp engineering documents remain valid after the inception of Sydney Trains, until the document references are replaced with a Sydney Trains or Asset Standards Authority equivalent.

2.1 Sydney Trains / Transport of NSW Documents • ESC 200 – Track System • ESC 215 – Transit Space • ESC 302 – Structures Defect Limits 30/08/2019 • TMC 301 – Structures Examination Manual • MN T 20203 – Track Inspection Manual • MN T 20101 – Track Service Schedules • MN C 10110 – Structures Service Schedules • MN C 10140 – Geotechnical Service Schedules v1.7, • T MU AM 01003 ST (Development of Technical Maintenance Plan) • T MU AM 01004 ST (Maintenance Service Schedule classification & Compliance) • MNA 00119 Maintenance Plan – Tunnels

00100 A MN by

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3 Definitions and Abbreviations The following definitions are used within this standard.

It integrates Enterprise Asset Management (EAM) functions across Transport Equip the Transport cluster through Transport Equip technology. Main lines include crossing loops, refuge loops and "sidings" where Mainline track: operating speed in excess of 25km/hr is possible. An asset/component whose functional failure or secondary damage Safety Critical resulting from the functional failure, either by itself or as a hidden Asset or function in concert with one other failure, will result in an increase in Component the likelihood of an incident which could involve significant injury to 30/08/2019 public or staff. The inability of a system or asset to perform its intended function or Failure inability to satisfy some predetermined conditional attribute. A task that protects against a failure mode (or root cause of a system failure) in a Safety Critical Asset/Component where the Safety Critical failure mode may be applicable to an individual asset/component Task (e.g. measurement of the gap in a single facing point lock that may drift beyond limits). v1.7, A task that: protects against an eventual possible failure mode (or root cause of Safety Significant a system failure) in a Safety Critical Asset/Component whose Task reliability performance is derived from that of a population of asset/components or is a quality check on staff performance on safety critical activities. Maintenance task should be completed within scheduled published Deviations for latitudes. A deviation from the published maintenance frequencies Preventive beyond published latitudes for all tasks requires approval from the appropriate engineering authority as detailed in PR A 00402 (under

00100 Maintenance review). If work is not completed within a specific time frame, it will require a REVCOM (Revised compliance). The common REVCOM process A will be used to approve the revision of all planned and corrective RevCom work. No deviation will be issued unless a satisfactory risk mitigation management process is in place. The aggregation of individual valid maintenance tasks into logically Task Packaging grouped packages to form service schedules. MN The minimum frequency at which relevant maintenance tasks should be carried out unless otherwise specified in Site Inspection Task Period Report (SIR). The term "various" indicate the specified frequency in SIR. by The allowed variance of a TMP task from its target date. Latitudes are for planning purposes, as tasks cannot always be completed on Task Planning the actual day due. Latitude The average time between maintenance events should still be in accordance with the specified task period. These examinations are detailed investigations of all aspects of the Detailed condition of a structure. These examinations involve close-up visual Structures examination of all members of the structure as detailed in the Examinations structures examination TMC 301.(TN 072: 2014) Close-up examination from within one meter is required for readily General accessible members of structures, member of bridges and OHWS. Structures Culverts, using mobile CCTV camera where necessary as detailed Examinations in the structures examination TMC 301.(TN 072: 2014)

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4 Maintenance Concept

4.1 General The maintenance concept provides for preventive maintenance schedules to minimise or avoid disruption to services, commensurate with Sydney Trains' safety and reliability objectives. There are two types of maintenance to support the system:

• Preventive maintenance • Corrective maintenance

30/08/2019 Note: Sydney Trains are installing axle counters on the rail network. Axle counters are a critical signalling train detection asset and must not be disturbed without prior approval from licenced signal personnel.

4.2 Preventive Maintenance Preventive maintenance is undertaken to keep an item in a specified operating condition through regular maintenance tasks and through systematic examination to detect and v1.7, prevent potential failures. The former of these includes routine servicing and regular scheduled maintenance based on time or traffic. The latter comprises surveillance examinations, condition monitoring and functional checks. The Technical Maintenance Plan details periods at which preventive maintenance is performed.

4.3 Corrective Maintenance Corrective maintenance is undertaken to restore items to a specified condition by repairing or replacing items. Corrective maintenance is carried out as a result of failures or unsatisfactory conditions detected during preventive maintenance examinations and 00100 checks. Corrective maintenance tasks are not detailed in the TMP.

A 5 Competency All maintenance inspection, assessment, monitoring and review functions shall only be carried out by accredited staff.

6 Safety Importance MN Not all safety related tasks are of equal importance, and therefore need different compliance regimes for cost-effective management. Sydney Trains has divided its assessed safety tasks into two categories, safety critical and safety significant. There are other tasks that are not directly safety related. by

The difference in importance between safety critical tasks and safety significant tasks is the failure characteristic of the condition being assessed by the examination task.

The failure characteristics of safety critical tasks are generally rapidly developing and adverse following the breach of defined conditional criteria. There is a significant increase in risk associated with safety critical tasks being extended beyond the specified task period without defined and approved risk mitigation measures in place.

The failure characteristics of safety significant tasks are slower to manifest themselves and less likely to be adverse following the breach of defined conditional criteria.

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7 Management and Reporting Senior Manager Civil Engineering (NMD), Senior Manager Track Engineering (NMD) and Maintenance Operations Manager (MOM) must establish and maintain systems to ensure that the following requirements for the completion of Safety related tasks are met:

1. Safety Critical and Safety Significant tasks shall be completed within the defined planning latitude. A TMP Deviation shall be sought for those tasks exceeding the planning latitude as referred in the Deviation for Preventive Maintenance Procedure PR A 00402 (under review). 2. Maintenance Operations Manager (MOM) shall review the compliance of Safety Significant and other tasks at the end of each month. 30/08/2019 3. A documented risk mitigation process designed to manage the increase in risk of extending the task period shall be provided to Engineering & System Integrity (E&SI) for those tasks exceeding the planning latitude. 4. All Deviations for Preventive Maintenance shall be documented. The records, including risk assessment, must be retained as per document retention standard.

WARNING v1.7, Failure to secure the appropriate Deviation will require IMMEDIATE (same day) action to bring the risk back to acceptable levels. This action may include seeking an Engineering TMP deviation for an extension, removal of the asset from service or placement of service restrictions on the particular asset.

7.1 Authority to Waive NMD can only exercise Engineering Authority to waive the conditions in Engineering 00100 Standards and Manuals that are specifically within the authority of Civil Maintenance Engineer. The authority of Civil Maintenance Engineer under MNA 00100 has been vested to the Senior Manager Civil Engineering & Senior Manager Track Engineering. In A these instances only Senior Manager Civil Engineering or Senior Manager Track Engineering has the Engineering Authority to approve local waiver. The local waiver is to be prepared and endorsed by the local Civil Engineer prior to be being submitted for approval to the NMD Senior Manager Civil Engineering or Senior Manager Track Engineering.

MN E&SI have the authority to deviate from conditions within Engineering Manuals. Only ASA can waive conditions in Engineering Standards. In both of these cases an application for a Concession is to be submitted to the E&SI Professional Head Civil or the E&SI Professional Head Track for consideration. The application for a Concession is to be

by prepared by the Local Civil Engineer and Endorsed by the NMD Senior Manager Civil Engineering or NMD Senior Manager Track Engineering before being submitted to E&SI. Senior Manager Civil Engineering or Senior Manager Track Engineering is NOT to submit Concession requests directly to ASA.

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8 Technical Maintenance Plan User Information The TMP table has the following elements:

• Asset group description • Safety Importance • Brief description of the preventive maintenance/service to be performed • Applicability of the Service to specified asset configurations or operating environments • Service Schedule reference 30/08/2019 • Minimum task frequencies or periods (including task planning latitudes) 8.1 Asset This element details relevant groups of assets within the civil discipline that share similar maintenance requirements e.g. track system, rail, sleeper/bearer, geotechnical, structures and right of way.

v1.7, 8.2 Service Description This column provides a brief description of preventive maintenance tasks or sets of tasks defined in the Service Schedule.

8.3 Safety Importance Some scheduled examination tasks have been categorised as Safety Critical (C) or Safety Significant (S). Tasks that are unscheduled (ON EVENT tasks) are shown as NA. 8.4 Applicability 00100 This column provides information about how preventive maintenance tasks are to be applied across various asset configurations and/or within specific operating environments. For example, the frequency of Track Patrols varies according the asset A type and traffic pattern. 8.5 Service Schedule Reference This column provides the alpha-numeric reference code of the Service Schedule applicable for the maintenance tasks. MN 8.6 Period The “Period” column defines the minimum frequency at which relevant maintenance should be carried out for each asset and configuration. by Note: There are several differences in frequency definitions between Transport Equip and MNA due to standardisation in strategy used in Transport Equip, which have been aligned for planning, rostering and track access cycles. This has resulted in a discrepancy in the total allowable latitude/compliance between the dates when the maintenance has been carried out. As such, for compliance standards, the information noted in the Civil TMP (MNA -00100) takes precedence over that defined in the Transport Equip system.

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Period references include:

ON EVENT Maintenance or examination is to be carried out when the relevant event occurs ON CONDITION Maintenance or examination is to be carried out when the item reaches a defined condition ATI Maintenance or examination is to be carried out At the Time of Installation Any reduction in the minimum recommended frequencies (lengthening time between tasks) must be authorised, as appropriate, through the Asset Standards Manager. Where criteria overlap the most stringent is to apply. For example if a section of track

30/08/2019 carries passengers services and freight traffic less than 1 Mgt per annum, two different track patrol frequencies might be seen to apply (two patrols per week and every 14 days). In this case the most stringent (two patrols per week) will apply.

8.7 Latitude This column specifies any latitude that may be allowed for scheduling purposes. The average time between maintenance events should still be in accordance with the

v1.7, specified minimum.

Latitudes are generally expressed in days. That is, a task with a period of four months and scheduling latitude of 12 days should be completed within a period of 120 + or - 12 days i.e. nominally 120 days, not more than 132 days and not less than 108 days between services.

Note: Early and late latitudes allowed/setup in EAM are dependent on scheduling parameters applied to the maintenance plans.

Note on Rounding 00100 When latitudes result in fractions of a day, they have generally been rounded up to whole days. This has been preferred over conventional rounding or explicitly rounding down.

A This was decided on the basis that a fraction of a day places the task in a particular day so the algorithm should use that day for calculations.

8.8 TMP Implementation Any TMP Updates/Changes from the previous version should be implemented according to implementation plan agreed with the business or as advised by Engineering & System MN Integrity (ESI).

9 Tailored Technical Maintenance Plans

by Approved Tailored Technical Maintenance Plans are detailed in E.

The information includes: • Location • Asset Class to which the Tailored TMP applies • Task to which the Tailored TMP applies (and a summary of its application)

10 Changes to TMP's and Updates Technical maintenance plans are developed by Asset Management Division of Sydney Trains in accordance to T MU AM 01003 ST. Sydney Trains uses a maintenance requirements analysis (MRA) approach to ensure that the technical maintenance plan is fit for purpose and is able to be referenced across the networks.

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Appendix A Technical Maintenance Plan Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments

30/08/2019 Description Importance Job no Schedule A-1 – Track System Standard Track C Heavy Freight Lines Maximum of 3 calendar days between days of examination Two per Patrol (Including Refuges and loops adjacent to tracks which N/A Example: This means that if patrol is carried out on Monday the week (Includes meet these criteria) next patrol can be carried out anytime on Friday Walking, hi-rail, Passenger Main Line v1.7, Adjacent Track Two per (Including Refuges and loops adjacent to tracks which N/A Maximum of 3 calendar days between days of examination Patrol and Night week meet these criteria) Patrol) P00001 SSC 001 Mixed Passenger Freight Main Line P00047 SSC 002 Two per (Including Refuges and loops adjacent to tracks which N/A Maximum of 3 calendar days between days of examination P00031 SSC 006 week meet these criteria)

Freight Main Line Two per carrying > 10mgt per annum N/A Maximum of 3 calendar days between days of examination (Including Refuges week and loops adjacent to 00100 tracks which meet carrying ≤10mgt per annum 7 days 1 day these criteria)

A Sidings Siding classifications are detailed in ESC200 – Track System

S Concrete track in P00033 SSC 001 28 days 3 days Signalled Track - includes all turnouts and catchpoints that are good condition interlocked and all rail which passes signalling current

Signalled & Turnouts in good MN Focal points Focal Points - locations at which a number of alternate routes Passenger condition on P08016 SSC051 14 days 1 day diverge/converge. If not signalled already such locations normally operations/ or concrete bearers abut signalled trackwork. maintenance centres and General Yards Other track 7 days 1 day by Primary Trackwork - includes all the areas of the yard where Primary Tracks including Manual 14 days 1 day rollingstock passes over regularly non-interlocking Levers Secondary Tracks including 28 days 3 days Secondary Trackwork - non-critical areas of track infrequently Manual non-interlocking Levers P00033 SSC 001 used Primary Tracks 14 days 1 day Passenger Sidings Secondary tracks 28 days 3 days Freight Sidings and Engineering Maintenance Sidings 28 days 3 days

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule Mainline track meeting ALL of the criteria detailed Integrated Track Patrol regime includes combinations of Walking P00001 SSC 001 Two per C N/A Patrol, Hi-rail Patrol, Engine Patrol, Mechanised Track Patrol AND in Appendix C. P00047 SSC 002 week Supplementary Patrol (where required) as determined by the P00048 SSC 003 30/08/2019 Ancillary track meeting ALL of the criteria detailed Senior Manager Track Engineering (NMD) to meet the C SSC 004 7 days 1 day in Appendix C. P00050 requirements of Appendix C Integrated Track Patrol Integrated Patrol regime includes combinations of Weekly Maximum Walking Patrol interval (ONLY applicable in Mechanised Track Patrol, Engine Patrol, Walking Patrol, Turnout C P00001 SSC 001 90 days 9 days association with Integrated Patrol regime) Patrol AND Supplementary Patrol (where required) as determined by the Maximum Turnout Patrol interval (ONLY applicable in Senior Manager Track Engineering (NMD) to meet the C P08016 SSC 051 28 days 3 days v1.7, association with Integrated Patrol) requirements of Appendix C Utilised as part of Integrated Track Patrol or to replace Standard Engine Patrol C Mainline track P00050 SSC 004 Various N/A Track Patrol as determined by the Track Engineering Manager (NMD) to meet the requirements of Appendix C. Examination of Plain track, BIJs or special trackwork in poor Supplementary ONLY applicable in association with Integrated Track C P00051 SSC 005 Various N/A condition as determined by the Senior Manager Track Patrol Patrol Engineering (NMD) to meet the requirements of Appendix C Wet Weather Event trigger: heavy rain, (dependent on infrastructure NA All track P00020 SSC 007 On event N/A

00100 Patrol susceptibility) Event trigger: During WOLO conditions and at times of high rail Heat Patrol NA Mainline Track with FFU / Timber Sleepers P00011 SSC 008 On event N/A temperature or when there is concern for the stability of welded A track Event trigger: Any event that may potentially cause track system Post Irregularity damage e.g. derailment, collision, flood or fire, earthquake, high NA All track P00006 SSC 011 On event N/A examination wind, (dependent on infrastructure susceptibility) or a "call out" based on reports from train drivers or the public MN Front of train S All mainline track P00002 SSC 009 14 days 5 days examination Heavy Freight Lines

by Passenger Main Lines SSC 010 3 months 18 days Contains a number of safety significant activities such as speed Mixed Passenger Freight Main Lines P00016 boards and sleeper condition carrying > 10mgt per annum Detailed walking Freight Main Lines S carrying ≤ 10mgt per annum SSC 010 6 months 36 days examination Sidings & Yards - General Yard, Passenger operations/ P02001 SSC 016 6 months 36 days or maintenance, Freight Siding and Passenger Siding To be performed / planned in alignment with SSC016. including Mechanical non-interlocking Levers P02003 SSC017 1 year 72 days SSC017 includes all tasks from SSC016 Engineering Maintenance Sidings P02001 SSC016 1 year 72 days

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule All Main lines 4 months 14 days Track recording S Crossing loops on all main lines P00004 SSC 021 8 months 28 days Twice frequency (i.e ½ as often) of adjacent main lines examination

30/08/2019 Olympic Park Sprint Platform Road - Lidcombe 1 year 36 days All mainline track Not required for tracks with solid concrete roadbed. Safety critical issues should be classified as a defect in 1 year 60 days S Examination should be conducted as per infringement list Track clearances high exposure areas and managed in Teams3 P00010 SSC 022 Infringement list to be reviewed each year examination Sidings 2 years 72 days Event trigger: Suspected change in which could NA All track On event N/A affect track clearances v1.7, Sleeper type Track curvature Slab track All radii 4 years 144 days Tangent track >1200m radius 4 years 144 days 1200 – 300m radius 2 years 72 days Concrete Clearance and < 300m radius 1 year 60 days coping S Unstable platform P21004 SSC 025 6 months 18 days Minimum measurement at Tangent track >1200m radius 4 years 144 days

00100 platforms 1200 – 300m radius 1 year 60 days FFU / Timber < 300m radius 1 year 60 days A Unstable platform 6 months 18 days Minimum Platforms with “Gap Reduction” strategies 6 months 18 days Unless an alternative inspection frequency has been authorised General Examination of S All platforms P21005 SSC 026 6 months 18 days Visual examination

MN clearance of platforms On multiple mainline track Optional where the design track centres for the appropriate rolling Some areas are more critical than others. Any area that S/C 1 year 36 days stock on the particular line exceed the minimum track design by Track Centres is < kinematic + 200 or not tangent, slab or fixed track P00009 SSC 023 centres as detailed in ESC215 by 300mm or more Examination (eg bridge deck) can be deemed as safety critical. Event trigger: Suspected change in track geometry which could NA Sidings On event N/A affect track centre clearances OHW/track Event trigger: Suspected change in track geometry which could alignment NA All track with OH Wiring P00005 SSC 024 On event N/A affect track/OHW relationship on electrified track Examination

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule To be completed by end of September each year. Where Welded Track seasonal factors prevent completion of examination/analysis a Stability S Main Lines and Main line Crossing Loops P00008 SSC 012 1 year 36 days preliminary assessment shall be made of any outstanding track.

30/08/2019 Examination The locations of any previous misalignments from the last 3 years shall be examined in detail prior to the end of September

To be completed by end of September each year. Main Lines and Main line Crossing Loops *Where seasonal factors prevent completion of Welded Track District waiver required if not completed by 1st October. examination/analysis a preliminary assessment shall be made of S* st P00032 SSC 013 1 year 36 days Stability Analysis Engineering waiver required if not completed by 1 any outstanding track. The locations of any previous November.

v1.7, misalignments from the last 3 years shall be examined in detail prior to the end of September.

Pre-Summer S Main Lines and Main line Crossing Loops P29002 SSC 015 1 year 36 days As the Summer approaches each year Inspection 00100 A MN by

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule A-2 – Rail System Detailed listing of lines and testing frequencies is shown

30/08/2019 Passenger lines (except as below) 4 months 14 days in Appendix B Sutherland to Cronulla, Metropolitan Goods lines, Pt Kembla line, Unanderra – Nowra, Lithgow to Bowenfels, Detailed listing of lines and testing frequencies is shown 6 months 1 month Nominated Crossing Loops, Refuge Loops and in Appendix B Platform Roads Hi Rail SSC 031 S Carlingford, Richmond lines, Darling Harbour, Botany P03001 Ultrasonic rail Detailed listing of lines and testing frequencies is shown v1.7, Lines and Homebush Loop, Crossing Loops in 1 year 2 months examination in Appendix B Metropolitan Area Manual P03002 Other regularly used crossing loops 2 years 72 days

All lines SSC 032 On Event N/A Event Trigger: Manual ultrasonic testing as required

All 53kg/m rails to be reused including for use as Event Trigger - proposed installation in main line. Includes NA SSC 032 On Event N/A closures examination for Vertical Split Head defects

00100 If found at night and full requirements for inspection cannot be carried out, defects classified as Medium (M) or larger shall be NA All Vertical Split Head defects - On Event Varies Visual reinspected in daylight hours the next day. Similarly Small (S) A Examination of TBA defects shall be reinspected in daylight hours within 7 days. VSH Rail Defects S Small Vertical Split Head defects - 14 days NIL To commence at end of 5 week period after detection

Rail wear and condition S All main lines and crossing loops P03003 SSC 033 1 year 36 days Rails that are visually wearing MN examination

Rail in Tunnels Rail corrosion S P00017 SSC 035 1 year 36 days by examination Other locations where corrosion is an actual or potential problem Rail in other wet locations (including electrolytic corrosion)

All new aluminothermic field welds P03006 SSC 036 14 days NIL To be tested after installation Test ATI where possible Test Weld S All new wirefeed welds P03007 SSC 037 14 days NIL To be tested after installation Test ATI where possible Cleaning Rail NA All rails NA NA On Event N/A Event Trigger: Clean or grind at time of installation head

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule All new rail installed on tracks with heavy duty and general freight traffic as part of re-railing (and not as closures for replacement of defects)

30/08/2019 To be profile ground within 5 MGT (or 20% of the grinding cycle Existing rail on ALL mainline tracks when concrete NA Grind Rail NA NA ATI N/A for preventive grinding (whichever is the larger) following the re- sleepers are installed. railing Existing rail on ALL mainline tracks when substantial backcanting is corrected. Cascading or transposing of rail on ALL mainline tracks All new rail installed on tracks with passenger traffic only To be profile ground within 10 MGT (or 20% of the grinding cycle NA NA as part of re-railing (and not as closures for replacement NA ATI N/A for preventive grinding (whichever is the larger) following the re-

v1.7, of defects) railing

Nominal Period Between Grinds (MGT) Tracks Tracks with Tracks with with Heavy General Passenger Duty Freight Traffic Freight Traffic or 3MGT or Traffic Empty Heavy 20% of Duty Freight cycle NA Traffic NA NA Various tonnage, 00100 Track Curvature (m) Std HH Std HH Std HH whichever is the 450 or larger A NA 20 15 20 20 30 less Grind Rail > 450 to (cont’d) 10 20 15 20 20 30 1000 > 1000 20 30 25 35 30 40 To be profile ground within 8 MGT for Standard Carbon rails and MN 10 MGT for Head Hardened rails (or 20% of the grinding cycle for New turnouts (or new turnout steelwork) on mainline preventive grinding of turnouts (whichever is the larger) following NA NA NA ATI N/A track installation.

by Use targeted grinding strategies for specific lines where approved through the Senior Manager Track Engineering (NMD) Rail Type NA 20% of The recommended guidelines for preventive rail grinding are to be NA 1:8.25 ≥ 1:15 NA NA Various cycle the more stringent of the requirements for the main line and for Head Hardened 13 18 25 tonnage the turnout road. Standard Carbon 8 13 18

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule Examination of Insulated Joints Electrified tracks 6 months 18 days (includes non- S P05001 SSC 038 30/08/2019 operational Non electrified tracks 1 year 36 days joints) Examination of Mechanical S Jointed mainline track P05002 SSC 039 1 year 36 days Visual as part of the Welded Track Stability Examinations. Joints All Mechanical Lubricators 6 months 18 days Rail Lubricator

v1.7, NA P28002 SSC 040 examination All Electrical Lubricators (Remotely monitored) On Event N/A Event trigger from remote monitoring

Rail Lubricator / Event trigger: to be filled and serviced at appropriate interval to TORFMA and NA All Lubricators / TORFMA and GFL Equipment P28001 SSC 041 As required N/A ensure service is carried our prior to lubricator running empty. GFL service Rail Lubricator check of rail NA All Lubricators P28005 SSC 042 On Event N/A Event trigger: Review lubrication prior to ultrasonic rail testing. head

00100 General NA TORFMA - (Solar panel & drive belt check) P28003 SSC043 1 year 36 days Or as required by specific equipment/situation Examination TORFMA – A Change battery & NA All TORFMA P28004 SSC044 5 year 180 days Or as required by specific equipment/situation calibrate Electronic Rail Lubricator - NA All Electric Rail Lubricators P28006 SSC 070 5 years 180 days Change Track MN Mount

Electronic Rail Lubricator – by NA All Electric Rail Lubricators P28007 SSC 071 10 years 365 days Change Electronics Sys

Electronic Rail Lubricator – NA All Electric Rail Lubricators P28008 SSC 072 15 years 440 days Change Grease Units

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule A-3 – Sleepers / Bearers Track with fully concrete sleepers/slabs 2 years 72 days

30/08/2019 Track with FFU / Timber sleepers 1 year 36 days Detailed Sleeper S P06001 SSC 046 Sidings with fully concrete sleepers/slabs 5 years 180 days examination Sidings with FFU / Timber sleepers 2 years 72 days S All track (Wet weather patrol) P00020 SSC 007 Variable N/A As part of Detailed walking Resilient S Resilient baseplates on FFU / Timber support 1 year 36 days baseplate P06005 SSC 047 v1.7, examination S Resilient baseplates on concrete support 2 years 72 days A-4 – Ballast Ballast S Welded Track P16001 SSC 048 1 year 36 days As part of Welded Track Stability Examination Examination A-5 – Turnouts Heavy Freight Lines Passenger Main Lines 00100 Examination of 1 year 36 days S Mixed Passenger Freight Main Lines Special Track P08001 SSC 052 Layouts carrying > 10mgt per annum A Freight Main Lines (including carrying ≤ 10mgt per annum 2 years 72 days turnout, Siding 2 years 72 days catchpoints, diamonds and S Complete service of manual non-interlocking Levers P02004 SSC066 2 years 72 days slips) S Examination of Manual Point Lever (Racor Lever) P02005 SSC067 14 days N/A As part of Track Patrol MN S Servicing of Manual Point Lever (Racor Lever) P02006 SSC068 3 months 18 days

Swing Nose S Level 1 Detailed Examination Applies to PRE and P08024 SSC 060 4 months 12 days As part of Detailed Walking Examination

by Crossing S Level 2 Detailed Examination VAE Swing nose P08025 SSC 061 1 year 36 days As part of Examination of Special Track Layouts Examination S Ultrasonic Examination installations P08026 SSC 064 6 months 18 days As part of Ultrasonic testing of crossing and turnout rails In-bearer S All locations P08001 SSC 052 1 year 36 days As part of Examination of Special Track Layouts examination Particular attention is drawn to any similar flexure turnouts (ie where the outside rail nominally the 'high rail' is the stockrail) Special Turnout which are subject to curve wear. For such cases, the fit of the S Similar flexure turnouts on main lines P08099 SSC 053 6 months 18 days examination switch against the stockrail, the condition of the switch, the stockrail and the switch tip height, width and angle should be assessed

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule Special Switch Interlocked points on FFU / Timber bearers (locations Event trigger: Prior to periods of extreme temperature such as FFU / Timber NA P09002 SSC 054 On event N/A with a history of points failures) Summer or Winter Examination

30/08/2019 After installation: 1 month for 12 months. NA Lines carrying > 15MGT per annum On event N/A Grinding: one off first month and as required after one month. Inspection of Reference: EI-T-18-01 & EI-T-18-02 Crossing P08004 SSC 055 After installation: Each month till first grind then each 3 months for condition 6 months NA Lines carrying ≤ 15MGT per annum On event N/A After repair (building up): each 2 months until first grind In service: as part of Turnout Examination v1.7, Examination of Additional examination due to ultrasonic examination being of Manganese S All manganese crossings P08028 SSC 063 3 months 9 days limited effectiveness crossings Visual For tangential turnouts where the main line route has been bent to Examination of a sharp curve and the high rail switch is subject to high wear Olympic Park and other nominated locations subject to High rail C P08005 SSC 056 7 days N/A rates. These locations shall be determined in conjunction with the high wear Tangential Senior Manager Track Engineering (NMD) Switches Can be done in conjunction with normal track patrol

00100 For tangential turnouts where the main line route has been bent to Wear a sharp curve and the high rail switch is subject to high wear Examination of Olympic Park and other nominated locations subject to rates. These locations shall be determined in conjunction with the

A High rail S P08003 SSC 057 2 months 6 days high wear Senior Manager Track Engineering (NMD) Tangential This period is to be reduced to one month should any significant Switches wear on the switches be detected Expansion switch S VAE 300mm Expansion Switches 1 year 36 days Where fitted. Examination to be completed during winter months P08008 SSC 058 examination S All OTHER Expansion switches 1 year 36 days at time of maximum switch contraction MN Ultrasonic testing S All Main Lines and Crossing Loops (except as below) 6 months 18 days of switches crossing and turnout rails P08002 SSC 062 by (including, S Unanderra – Nowra 1 year 36 days catchpoints, diamonds & slips) Ultrasonic Examination of S All Expansion switches P08007 SSC 065 6 months 18 days Expansion Switches Ultrasonic testing S Heeled switches with recorded crack predictors P08002 SSC 062 3 months 9 days of switches

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule A-6 – Drainage Event trigger: at times of heavy rain (>50mm in 24 hours) or Wet weather - 30/08/2019 potential flooding (includes functioning of drainage structures special NA All operational lines On event N/A such as trash racks, sedimentation basins and flow control examination P23003 SSC 091 structures) Prior to period of greatest rainfall (Aug or Dec) Surface drain S All operational lines 1 year 36 days (includes functioning of drainage structures such as trash racks, examination NA All sidings 1 year 36 days sedimentation basins and flow control structures) Sub-surface S All lines 1 year 36 days Prior to period of greatest rainfall (Aug or Dec) v1.7, drain examination NA All sidings 1 year 36 days Prior to period of greatest rainfall (Aug or Dec) P23003 SSC 091 Sub-surface Currently applicable to City inner and outer, up shore & down drain Rubbish S All operational lines (where applicable) 6 month 18 days shore, ESR Up and Down, Illawarra relief up and down, Engine collection Dive and Illawarra Dive up and down 6 months 18 days May be varied in accordance with operational criticality of system All Pump system 3 month 9 days CBD area only S P23005 SSC 242 examination All sumps and drainage pit structures 00100 1 year 36 days (where applicable)

A A-7 – Train Monitoring Equipment In conjunction with Track Patrol - Examination of Signs and All mainline locations (where installed) 7 days N/A Magnets present Track Magnet SSC 096 Routine In conjunction with Siding Patrol - Examination of Signs and S All siding locations (where installed) P01001 14 days N/A Maintenance Magnets present

MN Examination In conjunction with Detailed Walking - Examination of magnets All locations (where installed) SSC 096 6 months 18 days and fastenings A-8 – Track Equipment by Detailed All fixed buffer stops and lower order protection devices P15011 SSC 233 4 years 145 days S Examination All energy absorbing buffer stops P15029 SSC 234 1 year 36 days Includes friction and combination hydraulic/friction buffer stops Special After an impact from track machinery/rolling stock or following N/A All energy absorbing buffer stops P15030 SSC 235 On event - Examination damage by road or rail vehicles

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule A-9 – Earthworks

30/08/2019 General All Cuttings & Embankments which are not risk S P15009 SSC 404 1 year 36 days In conjunction with Detailed Walking Examination Examination assessed

All Cuttings which are not risk assessed P15031 SSC 400 Detailed Subject to the finding of General Examination (Job P15009) and S On event N/A Examination assessment from Civil Engineer. All Embankments which are not risk assessed P15032 SSC 401 v1.7, All risk rank A sites without EWS (slip detector) Continuous Safety critical sites should be classified as defects and None Event trigger: Prior to and during passage of trains in dry weather on event C managed separately. All risk rank A sites with EWS (slip detector) 1 day None

All risk rank B+ sites without EWS in wet weather 1 day None

Geotechnical risk All risk rank B+ sites without EWS in dry weather Two per week None

00100 site examination

(By Track patrol) All risk rank B+ sites with EWS in wet weather Two per week None For

All risk rank B+ sites with EWS in dry weather Cutting 1 month 6 days A P15031 SSC 400 * For monthly period, 6 days; otherwise in conjunction with All risk rank B-,P1 sites without EWS in wet weather Various * SSC 401 Detailed Walking Examination.

SSC 402 All risk rank B-,P1 sites without EWS in dry weather 1 month 6 days SSC 403

S All risk rank B-,P1 sites with EWS in wet weather 1 month 6 days MN * For monthly period, 6 days; otherwise in conjunction with All risk rank B-,P1 sites with EWS in dry weather Various * For Detailed Walking Examination.

Embank All risk rank B-,P2 sites without EWS in wet weather 1 month 6 days by P15032 Geotechnical risk * For monthly period, 6 days; otherwise in conjunction with All risk rank B-,P2 sites with EWS in wet weather Various * site examination Detailed Walking Examination. (By Track patrol) * For monthly period, 6 days; otherwise in conjunction with All risk rank B-,P2 sites without EWS in dry weather Various * Detailed Walking Examination. All risk rank C+P1, C+P2, C- and D sites with or without * For monthly period, 6 days; otherwise in conjunction with Various * EWS and in both wet and dry weather Detailed Walking Examination. Geotechnical risk All risk rank A sites without EWS (slip detector) 7 days None review inspection S P15034 SSC 405 for cutting and All risk rank A sites with EWS (slip detector) 1 month 3 days

© Sydney Trains Page 24 of 45 Date in Force: 27 June 2019 UNCONTROLLED WHEN PRINTED Version 1.6 Superseded Sydney Trains Engineering Manual – Common Civil and Track Technical Maintenance (extracted from formerly ESC 100) MN A 00100

Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule

embankments All risk rank B+ sites without EWS in wet weather 1 month 6 days

(By Geotech. All risk rank B+ sites without EWS in dry weather 1 month 6 days 30/08/2019 Engineer.) All risk rank B+ sites with EWS in wet weather 6 months 36 days All risk rank B+ sites with EWS in dry weather 6 months 36 days All risk rank B-,P1 sites without EWS in wet weather 6 months 36 days All risk rank B-,P1 sites without EWS in dry weather 6 months 36 days All risk rank B-,P1 sites with EWS in wet weather 6 months 36 days v1.7, All risk rank B-,P1 sites with EWS in dry weather 6 months 36 days All risk rank B-,P2 sites without EWS in wet weather 6 months 36 days All risk rank B-,P2 sites with EWS in wet weather 6 months 36 days All risk rank B-,P2 sites without EWS in dry weather 6 months 36 days All risk rank C+P1 sites with or without EWS and in both Various * * For 6-month period, 36 days; for 1- year period, 72 days) wet and dry weather 00100 All other risk rank C+P2, C- & D sites with or without 1 year 72 days EWS and in both wet and dry weather

A Monitoring of NA De-Vegetation around all inclinometer and piezometers P15035 - 1 year 36 days Geotechnical Instruments S Flushing of piezometers P15036 SSC406 2 year 72 days A-10 – Level Crossings Level crossings, track vehicle access points and track MN vehicle take offs on lines with passenger traffic S P24001 SSC 301 1 year 36 days Note – includes all signs and road markings examination Level crossings, track vehicle access points and track vehicle take offs on lines carrying more than 10mgt pa by Event Trigger: Changes to sight distance standards, notification of Sight distance NA All level crossings - TBA On event N/A changes in road or rail traffic patterns (volume, speed, vehicle Assessment type) A-11 – Structures SSC 200 Includes steel and concrete components of timber bridges and S All timber bridges on operational lines P26002 2 years 72 days SSC 201 timber components of steel or concrete bridges

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule P26036 All underbridges, overbridges and footbridges in poor 2 year (DT) Note: All steel underbridges (superstructure) over the age of 100 condition including masonry bridges SSC 200 S/C 2 year (G) 72 days years shall be considered as poor condition until a detailed/ All bridges with cast iron components SSC 201 30/08/2019 (see App D) engineering assessment determines its new examination regime (Note: One general examination in between two detailed)

As defined Steel includes Wrought and Cast iron All steel or concrete underbridges including flyover, SSC 200 in table 6 & S Variable Concrete includes reinforced and prestressed concrete, brick, and dives, multilevel stations, SSC 201 7 in stone bridges, PVC, or similar. Appendix D Detailed P25001 SSC 210 v1.7, S All steel or concrete overbridges 4 years 145 days Structures P25003 SSC 211 Examination P27001 SSC 213 S All steel or concrete footbridges including stepways* 4 years 145 days includes footbridges of compressed fibro SSC 214 P27003 Culvert P31001 SSC 204 All concrete or masonry culverts & pedestrian subway 4 years 145 days Subways SSC205 S P32001 Culverts includes undertrack pipes greater than 300m opening

00100 All steel culverts P31001 SSC 204 1 years 36 days

A All Overhead wiring structures and signal bridges Members identified as deteriorated during basic examination, but S All Combined OHW and Pantograph Condition P15019 SSC 220 4 years 145 days inaccessible from ground level, are to be noted for subsequent

Monitoring System bridges detailed examination under “power outage” conditions.

S All Tunnels P22001 SSC 222 4 years 145 days Ref: MNA 00119 All cattle stops, ash/sand traps, traffic barriers, bridge MN S balustrades, sedimentation basins storm water flow P21002 SSC 224 4 years 145 days controls and similar structures) Detailed S All air space developments P25005 SSC 225 4 years 145 days Structures by Examination Miscellaneous Structures: lighting towers, service crossings, loading banks & S stages, turntables, fixed cranes, weighbridges, overhead P21002 SSC 224 4 years 145 days water tanks, sedimentation basins, stormwater flow controls and similar structures, All Retaining Walls, Noise Abatement Walls and S P21001 SSC 223 4 years 145 days Platform Walls S Crib walls and reinforced soil walls P21001 SSC223 2 years 72 days

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule

S All track Rigid slabs P06003 SSC 227 2 years 72 days S All track Floating slabs P06004

30/08/2019 Depending on deterioration shown at the previous examination, or if major scouring is suspected. Underwater All underbridges with pier/column bases permanently Separate post flood examination to protect against occasional S P26038 SSC 230 6 years 216 days examination underwater damage - frequency should be based on condition or major structures over continuously moving waterway such as the Hawkesbury river or Como bridge

v1.7, Broad flange S All broad flange beams over roadways P26001 SSC 203 1 month 6 days beam exam

Event Trigger: during periods of heavy rain, of flooding, fire, Special NA All structures SSC 231 On event N/A earthquake, geotechnical activity or following damage by road or examinations rail vehicles. All timber transoms / on underbridges on operational lines.

00100 All FFU (Fibre Reinforced Foamed Urethane) Transoms P26050 SSC 208 1 years 36 days In conjunction with 90 days detailed walk (where practical) and Walkway components (including joists, bearers and decking material)

A General At least once in the period between Detailed Structures Structure All timber bridges SSC 202 2 year 72 days Examination UB examinations P26012 As defined Steel includes Wrought and Cast iron

All steel or concrete underbridges including flyover, in table 6 & Concrete includes reinforced and prestressed concrete, brick, and UB(Steel) SSC 202 Variable

MN dives, multilevel stations, 7 in stone bridges, PVC, or similar. This includes inspection of timber P26036 S Appendix D transoms over underbridges.

All steel or concrete overbridges* P25002 SSC 212 4 years 145 days (* The new TMP will be in line with underbridges) by General Structure All steel or concrete footbridges including stepways P27002 SSC 215 4 years 145 days Include footbridges of compressed fibro Examination All concrete culverts & pedestrian subway P31002 SSC 205 4 years 145 days Culverts includes undertrack pipes greater than 300m opening

All Overhead wiring structures and signal bridges All Combined OHW and Pantograph Condition P15020 SSC 221 4 years 145 days Monitoring System bridges

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule

All timber bridges 2 years 72 days

30/08/2019 All underbridges, overbridges & footbridges in poor 1 year 36 days condition including masonry bridges. To follow detailed structures examinations Structures As assessment of detailed examination results in order to ensure Assessment the continuing integrity of each structure. All other Under bridges Variable Variable (To follow Variable Latitude S P00041 SSC 232 detailed 1 year = 36 days structures All other overbridges, culverts, pedestrian subways 2 years = 72 days v1.7, examinations) tunnels, retaining walls over 2m high supporting rail 4 years 145 days 4 years = 145 days embankments or adjacent to mainline 6 years = 216 days

Piers & column above waterline after underwater 6 year 216 days examination

Engineering See NA All underbridges over 30 years of age P00055 30 years 3 years Engineering assessment includes fatigue assessment. Assessment Appendix D

00100 Structure Event trigger: Any irregular event potentially affecting the integrity damage NA All Structures P00042 SSC 231 On event N/A of the structure. E.g. Rail or road vehicle impact, flood, land assessment slide/slip, earth tremor, etc. A UB All underbridges, culverts and subways SSC 206 2 years 72 days P26054 OB NA P26055 All overbridges and footbridges SSC 216 4 years 145 days MN FB Routine Cleaning P26056 Surface drain / Track Slab S TBA 1 year 36 days Currently applicable to Boronia & Zigzag tunnels Jet / Hydrovac (where applicable) by Currently applicable to City inner and outer, up shore & down S Sub-surface drain - Jet / Hydrovac (where applicable) TBA 2 years 72 days shore, ESR Up and Down and Illawarra relief up and down UB All underbridges (where applicable) SSC 207 2 years 72 days P26032 Servicing of NA OB Bearings P26057 All overbridges and footbridges (where applicable) SSC 217 4 years 145 days FB P26058

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Technical Maintenance Plan Service Safety Standard Service Applicability Period Latitude Comments Description Importance Job no Schedule A-12 – Right of Way S All operational lines 1 year 36 Days As part of Detailed Walking Examination

30/08/2019 Right of Way P29001 SSC 310 (includes fencing , vegetation, access roads, firebreaks, vermin examination S All sidings 2 year 72 Days control, cattle grids, site litter control) Railway sign & S All lines 1 year 36 Days As part of Detailed Walking Examination 8 Car Markers P15008 SSC 311 Includes Speed boards and Safety Signs examination S All sidings 2 year 72 Days Permanent As part of Detailed Walking Examination - correctness of signs v1.7, Speed sign S All lines P15006 SSC 312 1 year 36 days (for position, speed shown , track indicated etc) examination In accordance with Signals TMP SC0780 “Field Equipment – Devices connected to signals (e.g. slip detector) - TBA 90 days 9 days Special warning Trackside Warning Devices” device S or as required by design for specific equipment/situation examination Other devices - TBA 1 month 6 days (includes, geotechnical and hydrological warning devices) Evacuation Signs City Underground Tunnels, North Sydney Tunnels, Cleaning & S P22006 SSC 240 1 year 36 days Eastern Suburbs Railway Tunnels, Airport Line Tunnels Inspection 00100 A MN by

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Appendix B Detailed Plain Track Rail Testing Schedule Line Section Kilometrage RIS Database North North Shore North Shore Up & Down 0.000 – 5.968 4 Months North Shore Gordon Up Road Platform 17.016 - 17.343 12 Months Epping to Chatswood Epping – Chatswood Up & Down 11.294 - 25.632 4 Months North Shore Lindfield Up Road Platform 12 Months Main North Main North Up & Down 12.759- 163.762 4 Months

30/08/2019 Main North Main North Suburban Up & Down 4 Months Main North Strathfield to Rhodes Relief Down 4 Months Main North Epping Refuge Down 4 Months Epping Up Main to Down Main Main North 4 Months Connection Pennant Hills to Thornleigh Relief Up & Main North 4 Months Down Main North Hornsby No1 Turnback Road Down 4 Months v1.7, Main North Hornsby No 2 Turnback Road 34.600 - 34.850 12 Months Main North Hornsby Down Refuge 34.100 - 34.600 6 Months Main North Hornsby Loop Up 4 Months Main North Berowra Loop Down 4 Months Main North Cowan Refuge Up 46.900 - 48.685 6 Months Main North Hawkesbury River Refuge Up 57.175 - 57.875 6 Months Main North Gosford Refuge Up & Down 81.010 - 81.598 6 Months Main North Wyong Refuge Up 100.735 - 101.160 6 Months Main North Awaba Refuge Up & Down 6 Months Main North Morisset Refuge Up 123.470 - 124.030 12 Months 00100 Main North Adamstown to Woodville Jct Relief Up 161.400 - 163.750 4 Months Main North Sulphide Jct Refuge Loop Up & Down 6 Months

A Main North Sulphide Jct Siding Up 152.778 - 153.330 12 Months Broadmeadow Via Broadmeadow via Relief Down 161.000 - 163.736 4 Months Dn Relief Broadmeadow Via Broadmeadow via Relief Down 163.736 - 164.295 8 Months Dn Relief Broadmeadow Yard Up & Down Main North 161.300 - 162.300 6 Months Through Road MN Woodville Jct To Woodville Jct to Newcastle Up & Down 163.762 - 164.408 4 Months Newcastle Hamilton Jct to Islington Hamilton Jct to Islington Jct Main Up & 163.797 - 168.216 4 Months Jct Down by Newcastle Newcastle Platform No3 & 4 Road 167.918 - 168.216 12 Months Illawarra Illawarra Illawarra Main Up & Down 2.800 - 59.939 4 Months Illawarra Illawarra Local Up & Down 2.800 - 15.036 4 Months Illawarra Illawarra Single Line 59.939 - 61.825 4 Months Illawarra Illawarra Main Up & Down 61.825 - 84.377 4 Months Illawarra Illawarra Single Line 84.377 - 85.324 6 Months Illawarra Illawarra Main Up & Down 85.324 - 87.844 6 Months Illawarra Illawarra Single Line 87.844 - 153.63 6 Months Illawarra Illawarra Loops Dapto - Kiama 12 Months Illawarra Nowra No 2 Down Goods Siding 153.221 - 153.600 12 Months Sutherland Platform Road & Platform Illawarra 6 Months Road to Cronulla Branch Connection

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Line Section Kilometrage RIS Database Inner Harbour Branch Up & Down, South Fork Flyover Up & Down, No.1-4 Arrival Inner Harbour Branch 6 Months Road & No.0-5 Departure Road, Oil Siding, No. 1-2 Storage Siding Unanderra North to Allens Creek Loop Coniston To Port Kembla 85.316 - 86.382 6 Months Triangle Inner Harbour Yard Port Corporation Coniston To Port Kembla 84.200 - 85.500 6 Months No1-2 Siding Coniston To Port Kembla Port Kembla Up & Down 84.317 - 88.644 6 Months Coniston To Port Kembla Port Kembla Refuge Loop Up 88.950 - 89.850 6 Months Coniston To Port Kembla Port Kembla Single Line 88.644 - 90.390 6 Months 30/08/2019 Illawarra Sutherland Refuge Up & Down 8 Months Illawarra Coalcliff Refuge Down 58.980 - 60.345 8 Months Thirroul Refuge Down, Refuge Loop Up, Illawarra 8 Months Platform Road Waterfall Goods Up, Refuge Loop Up & Illawarra 8 Months Down Illawarra Wollongong Refuge Up & Down 82.996 - 83.951 8 Months

v1.7, Sutherland to Cronulla Main Up & Down Sutherland To Cronulla 24.896 - 35.009 6 Months & Single Tempe To Glenfield Jct East Hills Local Up & Down 7.285 – 33.000 4 Months Tempe To Glenfield Jct East Hills Main Up & Down 4 Months New Southern Railway Airport Line Up & Down 4 Months Central North Shore North Shore Up & Down 5.968 - 25.397 4 Months Eastern Suburbs Eastern Suburbs Up & Down 4 Months Illawarra Illawarra Main Up & Down 0.510 – 2.800 4 Months

00100 Illawarra Redfern Eveleigh Dive Up 12 Months Illawarra Illawarra Local Up & Down 0.000 - 2.800 4 Months Illawarra Illawarra Relief Up & Down 0.000 - 2.800 4 Months

A Illawarra Central Illawarra Terminal Road Down 0.180 - 0.520 12 Months Illawarra Illawarra Dive Up & Down 1.430 - 2.365 4 Months Main Central Platform 23 Crossover 625 4 Months Main Sydney Platform No3 - 15 Road Platform 12 Months City Circle City Circle City Inner & City Outer 0.00 - 5.893 4 Months City Circle Central City Outer 2 Platform 23 4 Months MN City Circle Central City Inner 2 Platform 21 4 Months Main North Main North Up & Down 11.6 – 12.759 4 Months Suburban Suburban Up & Down 0.00 - 17.995 4 Months Main Main Up & Down 0.000 - 17. 995 4 Months by Local Local Up & Down 0.000 - 12.577 4 Months Main Ashfield Terminal Rd Road Platform 12 Months Main Strathfield Back Platform Road 4 Months Homebush Local Terminal Road Main 4 Months Platform Main Lidcombe Shuttle Road Up 4 Months Main Olympic Park Loop Inner Platform Loop 4 Months Flemington Homebush Bay West Fork Up & Down 4 Months Flemington Junction Homebush Bay Connection Single Line 15.078 - 15.328 4 Months Flemington Goods Connection Single Flemington Junction 15.192 - 15.374 6 Months Line Enfield East Fork Up & Down Loop Flemington Goods 19.813 - 20.100 6 Months Triangle Flemington Goods Flemington Goods Up 13.587 - 15.444 6 Months

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Line Section Kilometrage RIS Database Flemington Goods North Strathfield Goods Single Line 12.700 - 15.444 6 Months Olympic Park Loop Homebush Bay East Fork Up & Down 4 Months Olympic Park Loop Olympic Park Balloon Loop 4 Months Bankstown Line Bankstown Line Up & Down 5.113 - 22.730 4 Months Bankstown Line Bankstown Up Loop 12 Months Main South Main South Up & Down 16.740 – 17.995 4 Months Main South Lidcombe Western Loop Triangle 4 Months Main South Sefton Park Jct East Fork Down 4 Months Main South Sefton Park Jct East Fork Up 4 Months Botany Line Botany Line Up & Down & Single Line 6.663 – 16.000 12 Months 30/08/2019 Meeks Road East Fork Up & Down & Metropolitan Goods 6 Months North Fork Up Metrop Goods Up & Down (South Fork) Metropolitan Goods 12 Months & Down North Fork Metropolitan Goods Metropolitan Goods Up & Down 6.064 - 20.334 6 Months Chullora Jct To Sefton Chullora Jct North Fork Up 6 Months Park Jct Chullora Jct To Sefton Chullora Jct to Sefton Park Jct Up &

v1.7, 17.083 - 22.27 6 Months Park Jct Down West Main South Main South Up & Down 17.995 - 28.210 4 Months Main South Refuge Down 12 Months Main South Ingleburn Glenfield Loop Up 40.701 - 46.435 6 Months Main South Glenfield Terminating Road Platform 12 Months Main South Campbelltown Up Refuge 12 Months Main South Campbelltown Down Refuge 53.690 - 54.353 6 Months Main South Macarthur Terminating Road Up 12 Months 00100 Granville to Cabramatta Main Up & Granville To Cabramatta 4 Months Down Merrylands To Harris Park South West Inner & Outer Loop Triangle 4 Months A Main West Main Up & Down 17.500 - 155.78 4 Months Main West Main West Up & Down 155.780 - 171.427 6 Months Suburban Suburban Up & Down 17.230 - 47.655 4 Months Main West Blacktown Refuge & Loop Up 35.084 - 35.627 4 Months Main West Richmond Branch Up & Down 32.270 - 34.734 12 Months Blacktown to Richmond Branch Up & MN Blacktown To Richmond 34.726 - 60.550 12 Months Down & Single Blacktown To Richmond Blacktown to Richmond Branch Loops 12 Months Main West Penrith to Lithgow Refuges 109.223 - 110.437 12 Months Penrith No1 Down Siding & Up Road

by Main West 55.175 - 55.788 12 Months Platform Clarence Colliery Balloon Clarence Colliery Balloon Loop 12 Months Loop Lithgow Coal Stage No1 Down Main West 153.310 - 154.110 12 Months Reception Siding Down Clyde Branch Platform Road Up & Main 12 Months Platform Road to Up Branch Connection Clyde Up Yard Up & Down Through Main 12 Months Road Clyde to Carlingford Up & Down & Clyde To Carlingford 20.754 - 28.067 12 Months Single Rosehill To Sandown Rosehill to Sandown Single Line 22.302 - 24.163 12 Months Rosehill To Sandown Sandown Loop Down 23.680 - 24.186 12 Months

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Appendix C Implementation of Varied Track Patrol Arrangements

C-1 – Adjacent Track Patrol and Night Patrol Adjacent Track Patrols and Night Patrols allow the replacement of some Walking patrol with Adjacent Track Patrols and Night Patrols subject to the requirements detailed below. Adjacent Track Patrols and Night Patrols may only be implemented as part of a Tailored Technical Maintenance Plan approved through the Track Engineering Manager. Three patrol regimes are available, as follows, and as shown in Table 1. 30/08/2019 • Two daytime Adjacent Track Patrols plus one Walking Patrol of special trackwork (can be a Night Patrol). Adjacent tracks to be observed from both sides during the weekly cycle. • A daytime Walking Patrol plus one Engine Patrol plus one additional Standard Track Patrol of special trackwork • Two daytime Adjacent Track Patrols plus one Walking Patrol per fortnight (can be a Night Patrol), plus one Engine Patrol per fortnight. Walking Patrol and Engine Patrol are to be staggered so that one or other is undertaken each week. v1.7, An Adjacent Track Patrol is where the track is inspected from the adjacent track or from further away than the adjacent track but no more than a distance equivalent to two track widths.

Examinations of all plain track , turnouts and special trackwork Week 1 Week 2 Adjacent Track Adjacent Track Adjacent Track Adjacent Track Plain Track & Patrol Patrol Patrol Patrol 1 Special Walking Patrol Walking Patrol Trackwork OR OR 00100 Night Patrol Night Patrol

Plain Track Walking Patrol Engine Patrol Walking Patrol Engine Patrol A 2 Special Walking Patrol Walking Patrol Trackwork Plain Track & Walking Patrol Adjacent Track Adjacent Track 3 Special OR Engine Patrol Patrol Patrol Trackwork Night Patrol MN Table 1 – Adjacent Track patrol Regime

The following conditions apply to Adjacent Track Patrols: • by Adjacent tracks shall be observed from both sides during each weekly cycle.

C-2 – Engine Patrol A routine Track Patrol may be carried out from the front of an engine instead of by walking or by track vehicle. This may only occur: • where by Engine Patrol is included in an Integrated Track Patrol regime, OR • when a patrol opportunity is lost due to strike/loss of possession etc, a single standard patrol may be replaced by an Engine Patrol, OR • to supplement routine patrols such as during special events.

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The following conditions apply to Engine Patrols: • they cannot be used for consecutive routine track patrols except where permitted as part of an integrated track patrol regime, • the previous scheduled routine track patrol shall have been carried out normally, • Any serious safety issues identified shall be followed up with a site inspection. Use of Engine Patrols to replace a single standard patrol opportunity lost due to strike/loss of possession is subject to the following additional requirements: • use shall be approved by the Senior Manager Track Engineering (NMD) individual patrol requirements shall be reviewed by the Senior Manager Track Engineering (NMD)) for the patrol area 30/08/2019 • the Senior Manager Track Engineering (NMD) shall keep a written record of the use of engine patrols including date, locations patrolled by engine, last normal patrol date, and special inspections or patrol methods used • the Senior Manager Track Engineering (NMD) shall forward written advice of these details to the Professional Head Track (ESI), within 24 hrs.

v1.7, C-3 – Integrated Track Patrol Regime The "Integrated Track Patrol" regime allows the replacement of some Walking/Hi-rail patrols with Mechanised Track Patrol and Engine Patrol subject to the requirements detailed below. Four patrol regimes are available, as follows 1. Basic Integrated Patrol of all plain track, turnouts and special trackwork (See Table 2) This uses a combination of Walking Patrol, Engine Patrol, Mechanised Track Patrol and Supplementary Patrol It is applicable on main lines in the Metropolitan area. 00100 2. Special Integrated Patrol of all plain track, turnouts and special trackwork (See Table 3). This uses a combination of less frequent Walking Patrol with Engine Patrol, Weekly A Mechanised Track Patrol and Supplementary Patrol. It is applicable on main lines in the Metropolitan area. 3. Examinations of all plain track, turnouts and special trackwork in Hi-Rail Patrol Areas (See Table 4).

MN This uses a combination of Hi-Rail Patrol, Walking Patrol, Engine Patrol, Mechanised Track Patrol and Supplementary Patrol. It is applicable on main lines in Outer Suburban and Regional areas north of Hornsby, west of Emu Plains and south of Waterfall. by 4. Examinations of all ancillary lines (See Table 5). This uses a combination of Hi-Rail Patrol, Walking Patrol, Engine Patrol, Mechanised Track Patrol and Supplementary Patrol. It is applicable on relief lines, refuges, crossing loops, passing loops, goods loops, turnbacks and platform roads where the operating speed is ≤ 80kph. Where, for any reason, the standard patrol (Walking Patrol or Hi-Rail Patrol) cannot be undertaken on the day on which it is planned, it may NOT be substituted by an Engine Patrol. Senior Manager Track Engineering (NMD) may, however, authorise a delay of one day only. This would mean that Walking Patrol or Hi-Rail Patrol may be conducted on the eighth day after the previous Walking Patrol or Hi-Rail Patrol. Any further delay requires authorisation through the Professional Head Track (ESI).

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(EXTRACTS FROM EI 14/03 MTP Camera Failure Protocols) In the event that Mechanised Track Patrol cameras fail, alternative procedures may need to be implemented. Camera Failure Strategies ‘Track View’ Cameras • If one of the ‘Track View’ cameras has failed – is there a satisfactory track camera image (front or rear) available? Normal Day Light Conditions If YES – MTP Review can proceed (even using the Infrared Camera). 30/08/2019 If NO – The run has failed. A re-run must be programmed for the following day.

Tunnels and Low Light Areas (Infrared Camera) As there is only one Infrared Track camera, the run would fail. A re-run must be programmed for the following day.

v1.7, Notes: 1. Some sections may be affected by sunlight, shadowing, or over exposure. These sections can be reviewed using the ‘Rail Cameras’

‘Rail Cameras’ – Loss of One Camera If there is a loss of one of the ‘Rail Cameras’, then the response will vary depending on the track condition and the infrastructure involved; i.e. • Plain Track in good condition

00100 MTP review can proceed, assuming that the previous MTP review of this section had both ‘Rail Cameras’ working correctly. • Supplementary Patrol Areas and GIJ’s in poor condition A The section must be manually patrolled within 24 hours. • Turnouts and Special Trackwork The action required is dependant upon the current walking patrol frequency for that particular turnout / asset:

MN a. 7 day cycle – No further action. b 14 day cycle – Manually patrol within 7 days, and inspect the rail affected by the missing camera. (If turnout patrols are mid-cycle offset from the mechanised patrol, then this will be addressed by the next turnout patrol). by c. 28 day cycle – Manually patrol within 7 days, and inspect the rail affected by the missing camera.

‘Rail Cameras’ – Failure Criteria If there is a loss of more than one ‘Rail Camera’, the run has failed. A re-run must be programmed for the following day. There must not be failed ‘Rail Cameras’ on consecutive runs. If there were ‘Rail Camera’ failures on the previous patrol then a re-run is required.

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‘Easement View’ cameras Normal Day Light Conditions If one of the ‘Easement View’ cameras has failed, and there is a satisfactory ‘Easement View’ camera image (either Front or Rear), then the standard review can be undertaken using the alternative imagery. Tunnels and Low Light Areas (Infrared Cameras) If one of the ‘Infrared Easement View’ cameras has failed, and there is satisfactory ‘Infrared Easement View’ camera image (either Front or Rear), then the standard review can be undertaken using alternative imagery.

30/08/2019 Note: Upon commencement of using the Infrared Imagery system the Front Easement view will be darker due to less lighting. It is only permissible to use this camera imagery in this failure scenario for a maximum of 1 week in a row. Once equal light has been achieved on both cameras this requirement does not apply. If both cameras are lost, then there is a further alternative available which requires: The front of engine inspection having been satisfactorily completed by the patroller on the Mechanised Patrol vehicle, and

v1.7, Splicing the successfully recorded ‘Easement View’ imagery from the previous run, into the office review. This is required to provide context to the patroller. If these alternatives cannot be provided, the run has failed, and a re-run must be programmed for the following day.

General Requirements The actions apply to only those sections of track affected by the camera failure. If only small sections are affected, it may be more efficient to manually patrol those areas, rather than conduct a re-run.

00100 All missed camera sections are to be recorded on the Certification Form. The MTP team must accurately record all missed camera sections, and flag them for resolution.

A The basis of the altered requirements is that the camera failures are rare. The overall efficacy of the inspection regime should not be affected. If the camera failures were to become common, then the inspection regime would require a complete review and reassessment

MN by

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Examinations of all plain track , turnouts and special trackwork Week 1 Week 2 Walking Patrol Plain Track Walking Patrol Engine Patrol or Engine Patrol MTP Walking Patrol Turnouts and Special Walking Patrol Engine Patrol or Engine Patrol Trackwork MTP Additional examinations at locations where applicability requirements ARE NOT met Week 1 Week 2 Plain Track Supplementary Supplementary In Poor Condition Patrol Patrol 30/08/2019 Plain Track Glued Supplementary Supplementary Insulated Joints in Patrol Patrol Poor Condition Supplementary Patrol T/O and Special (if Turnout and Supplementary Supplementary Trackwork in Poor Special Trackwork Patrol Patrol Condition examination is by MTP) v1.7, Notes: • Two patrols per 7 day week • A maximum of 3 calendar days between consecutive examination days • MTP to occur at least every 14 days, with imagery review within 24hrs of patrol • (MTP can occur on 15th day, with imagery reviewed within 24hrs of patrol) • Common schedules to be aligned with each other • MTP & EP on running road through turnouts and special trackwork • Regime may also be used in Hi-Rail Patrol lengths in Outer Suburban & Regional areas. 00100 Table 2 – Basic Integrated Patrol – Main line

A MN by

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Integrated Walking examinations of all plain track , turnouts and special trackwork Week1 Week2 Week3 Week4 Plain Track MTP+ Engine Patrol + MTP + Engine Patrol + Engine Patrol Engine Patrol Engine Patrol Engine Patrol MTP+ ½ Walking Patrol + MTP + ½ Walking Patrol + Turnouts Option1 and Engine Patrol Engine Patrol Engine Patrol Engine Patrol Special MTP + Walking Patrol + MTP + Engine Patrol + Trackwork Option2 Engine Patrol Engine Patrol Engine Patrol Engine Patrol MTP+ Walking Patrol + MTP + Engine Patrol +

30/08/2019 CBD Engine Patrol Engine Patrol Engine Patrol Engine Patrol Tunnels MTP+ Engine Patrol + MTP + Engine Patrol + Other Engine Patrol Engine Patrol Engine Patrol Engine Patrol Additional examinations at locations where applicability requirements ARE NOT met Week1 Week2 Week3 Week4 Plain Track with known issues MTP + Engine Patrol + MTP + Engine Patrol+ v1.7, Engine Patrol Engine Patrol Engine Patrol Engine Patrol + Supplementary Patrol as required T/O and Special MTP + Walking Patrol + MTP + Walking Patrol + Trackwork with Engine Patrol Engine Patrol Engine Patrol Engine Patrol known issues + Supplementary Patrol as required Notes: • Plus Detailed Walking Patrol every 90 days for plain track • This requirement can be met by compliance with the requirements for Detailed Walking 00100 Examination, including the relevant latitude • Turnouts can be inspected by either Option 1 or Option 2. Option 1 allows for turnout inspections is to be staggered so half are done each second week A • Two patrols per 7 day week • A maximum of 3 calendar days between consecutive examination days • MTP to occur at least every 14 days, with imagery review within 24hrs of patrol (MTP can occur on 15th day, with imagery reviewed within 24hrs of patrol) • Common schedules to be aligned with each other MN • MTP & EP on running road through turnouts and special track work • Regime may also be used in Hi-Rail Patrol lengths in Outer Suburban & Regional areas.

Table 3 –Special Integrated Patrol– Main line by

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Examinations of all plain track , turnouts and special trackwork in Hi-Rail Patrol lengths in Outer Suburban & Regional areas Week 1 Week 2 Hi-Rail Patrol Plain Track Hi-Rail Patrol Engine Patrol or Engine Patrol MTP Hi-Rail Patrol Turnouts and Hi-Rail Patrol Walking Patrol or Engine Patrol Special Trackwork MTP Additional examinations at locations where applicability requirements ARE NOT met Week 1 Week 2 Plain Track In Poor Supplementary Supplementary

30/08/2019 Condition Patrol Patrol Plain Track Glued Supplementary Supplementary Insulated Joints in Patrol Patrol Poor Condition Supplementary Patrol T/O and Special (if Turnout and Special Supplementary Trackwork in Poor Trackwork examination Patrol Condition is by MTP) v1.7, Notes: • Two patrols per 7 day week. • A maximum of 3 calendar days between consecutive examination days. • MTP to occur at least every 14 days, with imagery review within 24hrs of patrol (MTP can occur on 15th day, with imagery reviewed within 24hrs of patrol) • Common schedules to be aligned with each other. • MTP and EP on running road through turnouts and special trackwork. Table 4 – Integrated Patrol – with Hi-Rail 00100 Examinations of all ancillary lines Week 1 Week 2 Walking Patrol Walking Patrol A Plain Track or or Hi-Rail Patrol Hi-Rail Patrol or MTP Walking Patrol Turnouts and Walking Patrol or Special Trackwork Hi-Rail Patrol or MTP Additional examinations at locations where applicability requirements ARE NOT met MN Week 1 Week 2 Plain Track Supplementary Supplementary In Poor Condition Patrol Patrol Plain Track Glued Supplementary Supplementary

by Insulated Joints in Patrol Patrol Poor Condition T/O and Special Supplementary Supplementary Trackwork in Poor Patrol Patrol Condition Notes: • One patrol per seven day week. • A maximum of seven calendar days between consecutive examination days. • MTP to occur at least every 14 days, with imagery review within 24hrs of patrol (MTP can occur on 15th day, with imagery reviewed within 24hrs of patrol) • Common schedules to be aligned with each other. • MTP and EP on running road through turnouts and special trackwork. Table 5 - Integrated Patrol – Ancillary lines

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C-4 – Applicability The Integrated Track Patrol regimes are ONLY applicable to track sections (including turnouts and special trackwork within the section) meeting the following mandatory requirements:

C-5 – Mandatory Requirements for Operation of the Integrated Walking Regime: The plain track, turnouts and special trackwork shall be tested weekly by MTP. Each track shall be individually walked.

30/08/2019 This regime shall not operate on whole tracks that are not signalled e.g. Kiama to Bomaderry Line. This regime shall not operate in Sydney Yard (between Central and Cleveland St), an area with very intense and complex turnout infrastructure.

C-6 – Mandatory Requirements for Mainline Track Sections: The plain mainline track within the section shall meet the following criteria: v1.7, 1. CONCRETE sleepered track, or 2. TIMBER sleepered track that satisfies ALL of the following criteria: • Rail is continuously welded (CWR). • Track is standard configuration. • The overall Track length is well tied for five years and sleepers provide adequate vertical support in accordance with the requirements of Engineering Manual MNT 20203 – Track Inspection, as assessed in Detailed Sleeper Examination Service Schedule SSC 046 (MNT 20101). 00100

C-7 – Mandatory Requirements for Ancillary Line Track Sections: A The ancillary line shall meet the following criteria: 1. For operating speeds > 50 kph and ≤ 80kph, the track section shall be fully concrete sleepered, CWR, signal track circuited and the turnouts and special track work shall have concrete bearers. This does not include turnouts and special trackwork connecting to the mainline, which are MN within the scope of the mainline patrols. If there are individual timber turnouts and special trackwork within a concrete sleepered ancillary line section, these turnouts and special trackwork require additional examination in accordance with Table 5. by 2. For operating speeds > 25 kph and ≤ 50 kph, the track section shall be CWR, signal track circuited and in moderate to good track condition considering speed and traffic. 3. For operating speeds ≤ 25kph or less, the track section shall be signal track circuited and in fair track condition considering speed and traffic.

C-8 – Conditions Requiring Supplementary Patrol Locations where the following requirements for additional examination apply shall be examined in accordance with additional examinations in Table 2, Table 4 and Table 5 above.

Rail affected by rail squats may require supplementary patrols. Current standards and any relevant Engineering Instructions should be considered in determining supplementary inspection requirement.

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C-9 – Plain track 1. Individual timber sleepered track locations that do not satisfy each of the following criteria, require Supplementary Patrol as per Table 2 or Table 4:

• track is well tied for 5 years and all sleepers within the vicinity of the location provide adequate vertical support in accordance with the requirements of MNT 20203 – Track Inspection as assessed in Detailed Tie/Sleeper Examination. • effective transoms in accordance with the requirements of MNC 10302, as assessed in Detailed Structures Examination. 2. Glued insulated joints (GIJs) in poor condition require Supplementary Patrol as per Table

30/08/2019 2, Table 4, as per Table 2 or Table 4, where any of the following criteria exist within the area of the GIJ:

• visible evidence of top or twist conditions (that may be assessed as P2 or worse) affecting the joint • visible signs of formation failure affecting the joint i.e. heaving beyond the ends of the sleepers or between the sleepers • bog holes affecting the joint i.e. track and ballast fouled and/or with mud pumping through v1.7, the ballast • chipped rail ends at GIJs and/or evidence of heavy impact (extensive whitened ballast • GIJ plates working loose • timber sleepers that do not meet "good sleeper" condition within 2m of the GIJ • timber transoms that do not meet "effective transom" condition within 2m of the GIJ.

C-10 – Turnouts and Special Trackwork

00100 Turnouts and special trackwork in poor condition (up to but excluding the insulated joint at the plain track interface) require Supplementary Patrol as per Table 2 or Table 4. Supplementary Patrol is required where any of the following criteria exist: A Conditions requiring inspection twice weekly by walking 1. Rail joints including non-glued insulated joints 2. 47kg/m, 53kg/m switches or heeled switches

MN Conditions requiring inspection twice weekly by walking 1. Joints with poor vertical support (flogging joint) within turnout, indicated by one or more of the following: • visible evidence of poor top or twist conditions (that may be assessed as P2 or worse) by affecting the joint • visible signs of formation failure affecting the joint. i.e. “heaving” beyond the ends of sleepers or between sleepers • “bog holes” affecting the joint. i.e. track and ballast fouled and/or with mud actively pumping through the ballast • chipped or battered rail ends at the rail joint and/or evidence of heavy impact (extensive whitened ballast) • loose bolts in joint, indicating Fish plates working loose 2. Joints with poor lateral support within turnouts or special trackwork i.e. sleepers/bearers/fastenings failed, or poor fastenings and bearers at crossing/checkrail. This will be indicated by bearers and sleepers not satisfying all of the following criteria:

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• effective bearers in accordance with the requirements of MNT 20203 – Track Inspection as assessed in Detailed Sleeper Examination and Examination of Special Track Layouts • sleepers and sleeper fastenings as per the plain track applicability requirements above 3. Locations with heeled switches (jointed) with the following conditions: • flogging heels or poor track condition in the area of the heel, as defined in 1. above • where the Rail flaw operators advise that strong crack predictors were assessed to be present in the heel of the switch or present in the closure rail at the heel • heels damaged in other ways, e.g. deformation or excessive wear in the heel block • proud rail ends and battered rail ends

30/08/2019 • flexible switches are not subject to this limitation. 4. Locations with K crossings on curves. 5. Locations with swing nose crossings in turnouts. There is insufficient experience with their behaviour at this time. This requirement will be reviewed when specific failure modes are better understood. Where heeled jointed main line turnouts are attached to loops, refuges, platform roads and turnbacks, and they are patrolled by foot each week as part of the Ancillary Line requirements, Supplementary v1.7, Patrol is not required.

C-11 – Ancillary Lines Ancillary lines with locations in poor condition require Supplementary Patrol, as per Table 5. Additional examination is required as per the conditions requiring additional examination on mainline track. When applying these requirements to ancillary lines, the speed and use of the line should be taken into account.

00100

A MN by

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Appendix D Examination Frequencies for Underbridges The frequency and type of examination required for steel and concrete underbridges are contained in table 6 & table 7. The type of examination required for bridge structure will vary depending on the age of the structure. The table below contain abbreviations for the type of examination required for underbridges. The definitions for those abbreviations are as follow; • DT means Detailed Structure • G means General Structural • EA means Engineering

30/08/2019 Examination Examination Assessment Table 6 – Underbridges 1 – 100 years Age (years) 1 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 Examinations DT DT DT DT G G DT G G DT G G DT G G DT + EA

v1.7, Age (years) 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 Examinations G G DT G G DT G G DT G G DT G G DT+EA

Age (years) 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 Examinations G G DT G G DT G G DT G G DT G G DT+EA

Age (years) 92 94 96 98 100 00100 Examinations G G DT G DT Table 7 – Underbridges 101 – onwards (till end of design life) A Age (years) 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 Examinations G DT G DT G DT G DT G DT G DT G DT G DT G DT G DT + EA

Age (years) 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 MN Examinations G DT G DT G DT G DT G DT G DT G DT G DT G DT G DT

Age (years) 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 by Examinations G DT G DT G DT G DT G DT+EA G DT G DT G DT G DT G DT

Age (years) 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 Examinations G DT G DT G DT G DT G DT G DT G DT G DT G DT G DT + EA Age (years) Age > 180 years ------One year Detail and next year General till remaining life of the structure plus EA every 30 years

Variable Latitude: 1 year = 36 days, 2 years = 72 days, 4 years = 145 days, 6 years = 216 day

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D-1 – Engineering Assessment (EA) Every steel or concrete underbridge must undergo an engineering assessment review at regular intervals by a suitably qualified professional engineer. The purpose of this review is to evaluate the safety, stability and functionality of the bridge structure, the conformity of its design and construction with good practice and safety standards and to determine appropriate remedial measures. The review must be conducted no later than 30 years after the commissioning of the new bridge and updated at least every 30 years. It should be noted that the examination frequency for a particular bridge can be reset as a result of EA findings. For bridges assessed to be in a poor condition defined below, the new examination frequencies shall be implemented only after an Engineering Assessment (EA) has been conducted and any identified remedial works have been carried out. It is to be noted that the EA might identify that it may be 30/08/2019 necessary to implement examination frequencies different from the standard new frequencies. For the remaining bridges, the new examination frequencies shall be implemented and a program of ‘catch up’ EAs, in ranking order based on condition shall be initiated. EAs must be completed within three years of commencement of the new examination frequencies for each bridge. For programming reasons it may be decided that for certain bridges, the current examination frequencies are to continue for a nominated timeframe. After the ‘catch up’ EA has been carried out, the next EA shall be undertaken in accordance with the v1.7, new examination frequencies. For example, if a bridge is 110 years old and its ‘catch up’ EA occurs at age 112 years then the next EA would be undertaken at age 120 years.

Steps involved in engineering assessment a. Collect background information on the bridge. (This shall include all relevant historical investigation, design, construction, remedial, operation and maintenance, monitoring and inspection data). b. Carry out a detailed examination of the bridge to assess all relevant condition parameters

00100 including detailed measurements of section loss to permit accurate assessment of ‘as is’ load rating. c. Carry out sufficient sampling and testing of materials for all major elements of the bridge to

A determine remaining life and associated relevant maintenance activities (for example, testing of depth of chloride penetration for estimating time to onset of corrosion). d. Compare the performance of the bridge with original design and assess the theoretical performance of the bridge against current standard and guidelines. e. In case of incomplete documentation, further investigation may be required for the first

MN engineering assessment. Typical investigation activities include: i. survey to establish lines and dimensions ii. testing of foundation material if required iii. geological drilling and mapping if required

by iv. research or calculate recent flood estimates v. updating of earthquake forces . Particular attention to be given to changes in operation of a bridge that may have occurred since construction. Check as to whether it can withstand appropriate loadings (including seismic) in accordance with current engineering practice. g. Recommendations shall be made for the following: i. live load ‘as new’ and ‘as is’ load rating ii. remaining fatigue life iii. necessary repairs including preliminary sketches and cost estimates iv. time frames for implementation of repairs v. any restrictions on operations required (for example load restriction) vi. any changes to the examination program vii. the adequacy of the bridge examination, operation and maintenance activities to date and any identified areas for improvement

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Engineering assessment is generally based on the age of the bridge and a maximum 30 year cycle but may also be initiated in response to issues such as: • an absence of design and construction documentation • a regulatory requirement • detection of abnormal behaviour • proposal to modify a bridge • changes in loading condition Asset Engineer must ensure that Bridge Management System (BMS) Engineer upload all engineering assessment reports in the appropriate database.

30/08/2019 Guidelines for determination of examination cycle based on bridge age The revised program of examinations for each bridge is based on the age of the bridge as defined in Appendix D: • if a bridge is 12 years old, it is due for a detailed examination • if a bridge is 33 years old, it is due for a general examination next year v1.7, Table 8: Guidelines for subjective rating of bridge condition

Subjective Rating Description

Excellent Free of defects more severe that category “E” defects

Free of defects affecting structural performance, integrity and Good durability

00100 Free of defects affecting structural performance, Defects Acceptable affecting the durability which require monitoring, detailed structural engineering inspection or maintenance A Defects affecting the performance and structural integrity of Poor the structure which require urgent action as determined by detailed structural engineering inspection

Unacceptable Bridge must be closed MN by

© Sydney Trains Page 45 of 47 Date in Force: 27 June 2019 UNCONTROLLED WHEN PRINTED Version 1.6 Superseded Sydney Trains Engineering Manual – Common Civil and Track Technical Maintenance (extracted from formerly ESC 100) MN A 00100

30/08/2019 v1.7, 00100 A MN by

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Appendix E Tailored Technical Maintenance Plans District Location Asset Class Task Document Reference Central Bondi Diamond Crossover Turnouts Track Inspection MN C 20102 North Epping to Chatswood Rail Line Track and turnouts Track Inspection MN C 20103 30/08/2019 Illawarra Stanwell Park Viaduct Underbridge Bridge Examination MN C 10111 Illawarra Georges River Bridge Como Underbridge Bridge Examination MN C 10112 North Hawkesbury River Bridge Underbridge Bridge Examination MN C 10113 West Knapsack Gully Viaduct Underbridge Bridge Examination MN C 10114 West Nepean River Bridge Underbridge Bridge Examination MN C 10115 v1.7, Central Woolloomooloo Viaduct Underbridge Bridge Examination MN C 10116 Illawarra Georges River East Hills Underbridge Bridge Examination MN C 10117 Central Rushcutters Bay Viaduct Underbridge Bridge Examination MN C 10118 North Chatswood Rail Enclosure Structure Tunnel Structures Examination MN C 10131 North Epping to Chatswood Rail Line Tunnels Tunnel Structures Examination MN C 10132 Central West Terrace Underbridge Bankstown Underbridge Structure Examination MN C 10119 00100 A MN by

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